Core-Shell Nanoparticle Synthesis via Plasma Aerosol Vaporization

Solution Overview

Problem

Existing methods for producing core-shell structured nanoparticles suffer from large particle size distribution and low production rates, limiting their effectiveness and efficiency.

Innovation Solution

A process involving a dry precursor powder or liquid/vapor containing core and shell materials suspended in an aerosol gas, passed through a plasma with a hot zone for vaporization and subsequent rapid cooling in an afterglow region, resulting in core-shell nanoparticles with controlled size and structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If previous methods are used to produce core-shell structured nanoparticles, then production can proceed with existing technology, but large particle size distribution and low production rates are obtained

Engineering Contradiction:

Improveparticle size distributionVSAvoidproduction rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The invention changes the physical state parameters of the precursor materials by using them in vapor form rather than solid or liquid form. The precursors are vaporized and introduced into a plasma environment, fundamentally altering the processing parameters to achieve both narrow particle size distribution and high production rates simultaneously

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention utilizes phase transitions by vaporizing the core and shell precursors and introducing them into a plasma environment where they undergo condensation and nucleation. This phase transition approach enables precise control over nanoparticle formation, achieving tight size distribution while maintaining high production throughput

Inventive Principle:

Principle #36Phase transitions

2Productivity

If previous methods are used to produce core-shell structured nanoparticles, then production can proceed with existing technology, but large particle size distribution is obtained

Engineering Contradiction:

Improveproduction rateVSAvoidparticle size distribution

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention changes the physical state parameters of the precursor materials by using them in vapor form rather than solid or liquid form. The precursors are vaporized and introduced into a plasma environment, fundamentally altering the processing parameters to achieve both narrow particle size distribution and high production rates simultaneously

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention utilizes phase transitions by vaporizing the core and shell precursors and introducing them into a plasma environment where they undergo condensation and nucleation. This phase transition approach enables precise control over nanoparticle formation, achieving tight size distribution while maintaining high production throughput

Inventive Principle:

Principle #36Phase transitions

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This process enables the production of core-shell nanoparticles with tight size distribution and high production rates, suitable for applications such as electroactive, catalyst, and hydrogen storage materials, with particle sizes as small as 50 nanometers and shell thicknesses under 20 nanometers.

Implementation Method 1

at least part of the core material and at least part of the shell material in the aerosol is vaporized

Methodology Applied

Scientific EffectVaporization: Evaporation

Implementation Method 2

passing the aerosol through the hot zone of the plasma

Methodology Applied

Scientific EffectPlasma heating: Heating

Implementation Method 3

The aerosol vapor initially transports the precursor into the plasma hot zone... the aerosol gas carries the new particles out of the hot zone and into a plasma after glow region where extremely rapid cooling occurs

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS8623470B2Process to make core-shell structured nanoparticles

Publication Date: 2014.01.07 STC UNM

AI summary

Disclosed is a process for making a composite material that contains core-shell structured nanoparticles. The process includes providing a precursor in the form of a powder a liquid and/or a vapor of a liquid that contains a core material and a shell material, and suspending the precursor in an aerosol gas to produce an aerosol containing the precursor. In addition, the process includes providing a plasma that has a hot zone and passing the aerosol through the hot zone of the plasma. As the aerosol passes through the hot zone of the plasma, at least part of the core material and at least part of the shell material in the aerosol is vaporized. Vapor that contains the core material and the shell material that has been vaporized is removed from the hot zone of the plasma and allowed to condense into core-shell structured nanoparticles.